Bottom chassis and method of manufacturing the same

ABSTRACT

A manufacturing method of a bottom chassis includes providing a base plate having a flexibility and a first rigidity through a press molding process, providing a bent-maintaining member having a second rigidity greater than the first rigidity and being curved in a first direction through an extrusion molding process, and coupling the base plate to the bent-maintaining member.

This application is a continuation of U.S. patent application Ser. No.14/599,658, filed on Jan. 19, 2015, which claims priority to KoreanPatent Application No. 10-2014-0042455, filed on Apr. 9, 2014, and allthe benefits accruing therefrom under 35 U.S.C. § 119, the contents ofwhich are hereby incorporated by reference in its entirety.

BACKGROUND 1. Field

The present disclosure relates to a bottom chassis and a method ofmanufacturing the same. More particularly, the present disclosurerelates to a bottom chassis having a curved shape and a method ofmanufacturing the bottom chassis.

2. Description of the Related Art

A display apparatus is used to display an image in various electronicequipment, such as a smart phone, a digital camera, a notebook computer,a navigation system, a smart television set, etc.

In recent years, a curved display device has been developed. The curveddisplay device generally includes a curved display area to provide auser with the image having improved three-dimensional effect,immersiveness, and virtual presence.

SUMMARY

The present disclosure provides a bottom chassis having improvedrigidity.

The present disclosure provides a method of manufacturing the bottomchassis in order to reduce a molding cost and improve reliability of thebottom chassis.

Exemplary embodiments of the invention provide a bottom chassisincluding a base plate having a flexibility and a first rigidity andbeing curved along a first direction and a bent-maintaining member whichhas a plurality of chassis bars coupled to the base plate, and maintainsa curved shape of the base plate, the plurality of chassis bars having asecond rigidity greater than the first rigidity, and being curved alongthe first direction. Each of the plurality of chassis bars is coupled toan adjacent chassis bar thereto.

In an exemplary embodiment, the base plate may include a bottom portionincluding first and second sides facing each other and the first andsecond sides extending substantially in parallel to the first direction.The bent-maintaining member may include a first bent-maintaining memberincluding first chassis bars of the plurality of chassis bars disposedadjacent to the first side and coupled to the bottom portion among thechassis bars and a second bent-maintaining member including secondchassis bars of the plurality of chassis bars disposed adjacent to thesecond side and coupled to the bottom portion among the chassis bars.

In an exemplary embodiment, the bottom portion may further include thirdand fourth sides extending in a second direction different from thefirst direction and substantially parallel to each other, the base platemay include first and second sidewalls respectively extending upwardfrom the third and fourth sides, and the third and fourth sides mayconnect the first and second sides to each other.

In an exemplary embodiment, both ends of each of the first and secondbent-maintaining members may be coupled to the first and secondsidewalls, respectively.

In an exemplary embodiment, each of the first and secondbent-maintaining members may include a first side chassis bar disposedadjacent to the first sidewall and a second side chassis bar disposedadjacent to the second sidewall, one end of the first side chassis baris coupled to the first sidewall by a first fixing member, an end of thefirst side chassis bar opposing the one end thereof is coupled to anadjacent first chassis bar of the first chassis bars, one end of thesecond side chassis bar is coupled to the second sidewall by a secondfixing member, and an end of the second side chassis bar opposing theone end thereof is coupled to an adjacent second chassis bar of thesecond chassis bars.

In an exemplary embodiment, each of the plurality of chassis bars mayinclude a body part, a first coupling plate protruded outward from oneend of the body part, and a second coupling plate protruded outward froman end of the body part opposing the one end thereof. The first couplingplate of each of the plurality of chassis bars is coupled to the secondcoupling plate of the adjacent chassis bar thereto.

In an exemplary embodiment, an upper surface of the first coupling platemay extend from an upper surface of the body part, a lower surface ofthe second coupling plate extends from a lower surface of the body part,the first and second coupling plates have thicknesses, respectively,which are smaller than a thickness of the body part, and a sum of thethickness of the first coupling plate and the thickness of the secondcoupling plate is equal to the thickness of the body part.

In an exemplary embodiment, the bottom chassis may further include afixing member that connects the adjacent chassis bars to each other andfixing the coupled chassis bars to the base plate.

In an exemplary embodiment, first and second holes may be definedthrough the first and second plates, a third hole may be defined throughthe base plate, and the fixing member includes a screw engaged with thefirst, second, and third holes.

In an exemplary embodiment, each of the plurality of chassis bar mayinclude a body part, a coupling block protruded outward from one end ofthe body part, and a coupling groove defined at an end of the body partopposing the one end thereof and having a shape corresponding to a shapeof the coupling block. The coupling block of each of the plurality ofchassis bars is coupled to the coupling groove of the adjacent chassisbar thereto.

In an exemplary embodiment, the coupling block may include a firstcoupling protruding part extending in the first direction from the bodypart and a second coupling protruding part extending in a directiondifferent from the first direction from an end of the first couplingprotruding part. The coupling groove includes a first coupling grooveportion having a shape corresponding to the first coupling protrudingpart and a second coupling groove portion having a shape correspondingto the second coupling protruding part.

In an exemplary embodiment, the bottom chassis may further include afixing member that connects the adjacent chassis bars to each other andfixes the coupled chassis bars to the base plate.

In an exemplary embodiment, a first hole may be defined through thefirst coupling protruding part, a second hole may be defined through theend of the body part opposing the one end thereof, a third hole may bedefined through the base plate, and the fixing member may include ascrew engaged with the first, second, and third holes.

Exemplary embodiments of the invention provide a method of manufacturinga bottom chassis including providing a base plate having a flexibilityand a first rigidity through a press molding process, providing abent-maintaining member having a second rigidity greater than the firstrigidity and being curved in a first direction through an extrusionmolding process, and coupling the base plate to the bent-maintainingmember.

In an exemplary embodiment, the providing the bent-maintaining membermay include providing an extrusion plate through the extrusion moldingprocess to curve the extrusion plate in the first direction, cutting theextrusion plate along the first direction to provide a plurality ofchassis bars, and coupling the plurality of chassis bars to each other.

In an exemplary embodiment, the extrusion plate may be extruded in asecond direction substantially perpendicular to the first direction.

In an exemplary embodiment, the extrusion plate may include first andsecond plate sides substantially in parallel to the second direction andthe first and second plate sides include first and second couplingpatterns, respectively.

In an exemplary embodiment, the base plate may include first and secondsides facing each other and extending substantially in parallel to thefirst direction. The bent-maintaining member includes a firstbent-maintaining member disposed adjacent to and coupled to the firstside and a second bent-maintaining member disposed adjacent to andcoupled to the second side.

In an exemplary embodiment, the base plate may further include third andfourth sides extending substantially in parallel to the second directionand first and second sidewalls respectively extending upward from thethird and fourth sides. The third and fourth sides connect the first andsecond sides to each other.

In an exemplary embodiment, both ends of each of the first and secondbent-maintaining members may be coupled to the first and secondsidewalls, respectively.

According to the above, since the chassis bars, which are provided bythe extrusion molding process to have the relatively strong rigidity,are coupled to the base plate, the rigidity of the bottom chassis isimproved. The chassis bars maintain the curved shape of the base plate.Therefore, the base plate does not need to have the curved shape wheninitially provided, and thus the manufacturing cost of the base plate isreduced and the reliability of the base plate is improved. In addition,the bent-maintaining member is provided by coupling the chassis bars toeach other, and thus the bent-maintaining member may be applied to thedisplay device having various sizes.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other advantages of the present disclosure will becomereadily apparent by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view showing an exemplary embodiment of adisplay device according to the present disclosure;

FIG. 2 is a perspective view showing a bottom chassis shown in FIG. 1;

FIG. 3 is a perspective view showing a first chassis bar shown in FIG.2;

FIG. 4 is an enlarged perspective view showing a portion in which firstand second chassis bars are coupled to the bottom chassis;

FIG. 5 is a cross-sectional view showing a portion in which a secondside chassis bar is coupled to a second sidewall;

FIG. 6 is a cross-sectional view showing a portion in which a first sidechassis bar is coupled to a first sidewall;

FIG. 7 is a perspective view showing another exemplary embodiment of achassis bar according to the present disclosure;

FIG. 8 is an enlarged perspective view showing a portion in which thechassis bar shown in FIG. 7 is coupled to the bottom chassis; and

FIGS. 9A to 9D are perspective views showing an exemplary embodiment ofa method of manufacturing a bottom chassis according to the presentdisclosure.

DETAILED DESCRIPTION

It will be understood that when an element or layer is referred to asbeing “on,” “connected to” or “coupled to” another element or layer, itcan be directly on, connected or coupled to the other element or layeror intervening elements or layers may be present. In contrast, when anelement is referred to as being “directly on,” “directly connected to”or “directly coupled to” another element or layer, there are nointervening elements or layers present. Like numbers refer to likeelements throughout. As used herein, the term “and/or” includes any andall combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, etc. maybe used herein to describe various elements, components, regions, layersand/or sections, these elements, components, regions, layers and/orsections should not be limited by these terms. These terms are only usedto distinguish one element, component, region, layer or section fromanother region, layer or section. Thus, a first element, component,region, layer or section discussed below could be termed a secondelement, component, region, layer or section without departing from theteachings of the invention.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,”“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. In an exemplary embodiment, whenthe device in the figures is turned over, elements described as “below”or “beneath” other elements or features would then be oriented “above”the other elements or features. Thus, the exemplary term “below” canencompass both an orientation of above and below. The device may beotherwise oriented (rotated 90 degrees or at other orientations) and thespatially relative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularexemplary embodiments only and is not intended to be limiting of theinvention. As used herein, the singular forms, “a,” “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“includes” and/or “including,” when used in this specification, specifythe presence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

“About” or “approximately” as used herein is inclusive of the statedvalue and means within an acceptable range of deviation for theparticular value as determined by one of ordinary skill in the art,considering the measurement in question and the error associated withmeasurement of the particular quantity (i.e., the limitations of themeasurement system). For example, “about” can mean within one or morestandard deviations, or within ±30%, 20%, 10%, 5% of the stated value.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

Exemplary embodiments are described herein with reference to crosssection illustrations that are schematic illustrations of idealizedembodiments. As such, variations from the shapes of the illustrations asa result, for example, of manufacturing techniques and/or tolerances,are to be expected. Thus, embodiments described herein should not beconstrued as limited to the particular shapes of regions as illustratedherein but are to include deviations in shapes that result, for example,from manufacturing. For example, a region illustrated or described asflat may, typically, have rough and/or nonlinear features. Moreover,sharp angles that are illustrated may be rounded. Thus, the regionsillustrated in the figures are schematic in nature and their shapes arenot intended to illustrate the precise shape of a region and are notintended to limit the scope of the present claims.

Hereinafter, the invention will be explained in detail with reference tothe accompanying drawings.

FIG. 1 is a perspective view showing a display device 1000 according toan exemplary embodiment of the present disclosure.

Referring to FIG. 1, the display device 1000 includes a bottom chassis100, a top chassis 200, and a display panel 300 interposed between thebottom chassis 100 and the top chassis 200.

The display device 1000 has a curved shape. In an exemplary embodiment,the display device 1000 is curved along a first direction D1, but itshould not be limited thereto or thereby. That is, in other exemplaryembodiment, the display device 1000 may be curved in various directions.The bottom chassis 100, the top chassis 200, and the display panel 300may have the curved shape in the first direction D1.

The display panel 300 includes a display area DA in which an image isdisplayed. The display area DA is curved to correspond to the displaypanel 300, and thus the display area DA has the curved shape. Therefore,the display panel 300 may display the image having improvedthree-dimensional effect, immersiveness, and virtual presence using thedisplay area DA having the curved shape.

The display panel 300 includes an array substrate 310, an oppositesubstrate 320, and a liquid crystal layer (not shown). The oppositesubstrate 320 faces the array substrate 310 while being coupled to thearray substrate 310, and the liquid crystal layer is interposed betweenthe array substrate 310 and the opposite substrate 320. A whole or aportion of the array substrate 310 has the curved shape along the firstdirection D1 and the opposite substrate 320 has the curved shapecorresponding to that of the array substrate 310.

The display panel 300 includes a plurality of pixels PX arranged in amatrix form in the display area DA. Each pixel PX generates the image inresponse to a signal applied thereto.

In an exemplary embodiment, the display panel 300 may include variousdisplay panels such as an organic light emitting display panel, a liquidcrystal display panel, a plasma display panel, an electrophoreticdisplay panel, etc.

The top chassis 200 is disposed on the display panel 300 to protect thedisplay panel 300 from external impacts. An opening which exposes thedisplay area DA of the display panel 300 may be defined in the topchassis 200. The top chassis 200 is coupled to the bottom chassis 100such that the display panel 300 is disposed between the bottom chassis100 and the top chassis 200.

The bottom chassis 100 is disposed under the display panel 300 toaccommodate the display panel 300 therein. The bottom chassis 100includes a base plate 110 and first and second bent-maintaining members120 a and 120 b, which are coupled to the base plate 110. The bottomchassis 100 provides a receiving space, which is defined by the baseplate 110 and the first and second bent-maintaining members 120 a and120 b, to accommodate the display panel 300.

FIG. 2 is a perspective view showing the bottom chassis 100 shown inFIG. 1.

Referring to FIG. 2, the base plate 110 includes a bottom portion 111and a sidewall extending upward from the bottom portion 111. The displaypanel 300 (refer to FIG. 1) is placed on the bottom portion 111. Thebottom portion 111 has a shape corresponding to that of the displaypanel 300. In an exemplary embodiment, the bottom portion 111 has arectangular shape, in a plan view, with two pairs of parallel sides, forexample. In the illustrated exemplary embodiment, the bottom portion 111includes a first side S1 extending substantially in parallel to thefirst direction D1 and a second side S2 facing the first side S1. Inaddition, the bottom portion 111 includes a third side S3 extendingsubstantially in parallel to the second direction D2 different from thefirst direction D1 and a fourth side S4 facing the third side S3. In anexemplary embodiment, the second direction D2 may be substantiallyperpendicular to the first direction D1. The third and fourth sides S3and S4 connect the first and second sides S1 and S2.

As described above, since the bottom chassis 100 has the curved shapealong the first direction D1, the first and second sides S1 and S2 havethe curved shape along the first direction D1. In more detail, the firstand second sides S1 and S2 are convex-downward to have the curved shape.In an exemplary embodiment, the bottom chassis 100 is not curved in thesecond direction D2. That is, the third and fourth sides S3 and S4 arestraight or linear in the second direction D2.

The third and fourth sidewalls S3 and S4 extend upward from the sides ofthe base plate 110, which are not curved. In the illustrated exemplaryembodiment, the base plate 110 includes first and second sidewalls SW1and SW2 respectively extending upward from the third and fourth sides S3and S4 that extend straight or in a linear direction.

The first and second bent-maintaining members 120 a and 120 b aredisposed respectively adjacent to the first and second sides S1 and S2and coupled to the bottom portion 111 along the first direction D1. Eachof the first and second bent-maintaining members 120 a and 120 bincludes a first chassis bar CB1, a second chassis bar CB2, a first sidechassis bar SB1, and a second side chassis bar SB2, which are coupled tothe bottom portion 111. In the illustrated exemplary embodiment, each ofthe first and second bent-maintaining members 120 a and 120 b includesone first chassis bar CB1 and one second chassis bar CB2, but the numberof the first and second chassis bars CB1 and CB2 should not be limitedthereto or thereby. In another exemplary embodiment, each of the firstand second bent-maintaining members 120 a and 120 b may include pluralfirst chassis bars and plural second chassis bars, for example.

The first and second chassis bars CB1 and CB2 are disposed between thefirst and second side chassis bars SB1 and SB2. The first side chassisbar SB1 is disposed between the second chassis bar CB2 and the firstsidewall SW1 and the second side chassis bar SB2 is disposed between thefirst chassis bar CB1 and the second sidewall SW2.

One end of the first chassis bar CB1 is coupled to one end of the secondside chassis bar SB2 and the other end of the first chassis bar CB1 iscoupled to one end of the second chassis bar CB2. The other end of thesecond chassis bar CB2 is coupled to one end of the first side chassisbar SB1.

One end of each of the first and second bent-maintaining members 120 aand 120 b is coupled to one end of the first sidewall SW1 and the otherend of each of the first and second bent-maintaining members 120 a and120 b is coupled to one end of the second sidewall SW2. In more detail,the other end of the first side chassis bar SB1 corresponding to the oneend of each of the first and second bent-maintaining members 120 a and120 b is coupled to the one end of the first sidewall SW1, and the otherend of the second side chassis bar SB2 corresponding to the other end ofeach of the first and second bent-maintaining members 120 a and 120 b iscoupled to the one end of the second sidewall SW2. In an exemplaryembodiment, a third coupling screw SC3 may be engaged with the firstsidewall SW1 and the first side chassis bar SB1.

The first and second sidewalls SW1 and SW2 have a first height h1 froman upper surface of the bottom portion 111. The first and second chassisbars CB1 and CB2 and the first and second side chassis bars SB1 and SB2have a first thickness th1. In the illustrated exemplary embodiment, thefirst height h1 may be substantially the same as the first thicknessth1, for example. The receiving space, in which the display panel 300 isaccommodated, is defined by the first and second bent-maintainingmembers 120 a and 120 b and the first and second sidewalls SW1 and SW2.

The base plate 110 has flexibility and a first rigidity, and the firstand second chassis bars CB1 and CB2 and the first and second sidechassis bars SB1 and SB2 have a second rigidity greater than the firstrigidity. Since the base plate 110 has the flexibility, the base plate110 may be bent by external force. In an exemplary embodiment, the baseplate 110 may include a metal plate having a thickness appropriate tohave the flexibility, for example.

In an exemplary embodiment, the first and second chassis bars CB1 andCB2 and the first and second side chassis bars SB1 and SB2 include amaterial having no flexibility in order to maintain the shape of thebase plate 110. That is, the first and second chassis bars CB1 and CB2and the first and second side chassis bars SB1 and SB2 are not bent eventhough the external force is applied thereto. In an exemplaryembodiment, the first and second chassis bars CB1 and CB2 and the firstand second side chassis bars SB1 and SB2 may include a metal platehaving a thickness inappropriate to have the flexibility. When a metalmaterial is provided, a metal member provided by an extrusion moldingprocess has the rigidity greater than that of a metal member provided bya press molding process. Accordingly, in an exemplary embodiment, thebase plate 110 is provided by press-molding the metal material, and thefirst and second chassis bars CB1 and CB2 and the first and second sidechassis bars SB1 and SB2 are provided by extrusion-molding the metalmaterial.

As described above, since the first and second bent-maintaining members120 a and 120 b, which are provided by the extrusion molding process andhave the rigidity greater than that of the base plate 110, are coupledto the base plate 110, the rigidity of the bottom chassis 100 isimproved.

A production cost of the base plate 110 when the base plate 110 isprovided to have the curved shape is expensive compared to a productioncost of the base plate 110 when the base plate 110 is provided to have aflat shape.

However, according to the exemplary embodiment, when the base plate 110is coupled to the first and second bent-maintaining members 120 a and120 b, the base plate 110 is bent to correspond to the shape of thefirst and second bent-maintaining members 120 a and 120 b even thoughthe base plate 110 is provided to have the flat shape when initiallyprovided. Therefore, the base plate 110 does not need to have the curvedshape when initially provided. Thus, the base plate 110 may be providedto have the flat shape when initially provided, so that the productioncost of the base plate 110 and the bottom chassis 100 may be reduced.

FIG. 3 is a perspective view showing the first chassis bar shown in FIG.2, and FIG. 4 is an enlarged perspective view showing a portion in whichthe first and second chassis bars are coupled to the bottom chassis.Since the first and second chassis bars CB1 and CB2 have the samestructure and function, hereinafter, only the first chassis bar CB1 willbe described in detail.

Referring to FIGS. 3 and 4, the first chassis bar CB1 is curved alongthe first direction D1 and includes a body part BM, a first couplingplate CP1 provided at one end of the body part BM, and a second couplingplate CP2 provided at the other end of the body part BM.

The body part BM includes a first surface A1 disposed at the one end ofthe body part BM which connects a lower surface of the body part BM anda lower surface of the first coupling plate CP1, and a second surface A2disposed at the other end of the body part BM to connect the uppersurface of the body part BM and an upper surface of the second couplingplate CP2.

The first coupling plate CP1 is protruded outward from the first surfaceA1. In an exemplary embodiment, the first coupling plate CP1 has athickness smaller than a thickness th2 of the body part BM. An uppersurface of the first coupling plate CP1 extends from the upper surfaceof the body part BM in a direction substantially in parallel to theupper surface of the body part BM. The first coupling plate CP1 includesa third surface A3 substantially in parallel to the first surface A1 andconnecting lower and upper surfaces of the first coupling plate CP1.

The second coupling plate CP2 is protruded outward from the secondsurface A2. In an exemplary embodiment, the second coupling plate CP2has a thickness smaller than the thickness th2 of the body part BM. Alower surface of the second coupling plate CP2 extends from the lowersurface of the body part BM. The second coupling plate CP2 includes afourth surface A4 substantially in parallel to the second surface A2 andconnecting lower and upper surfaces of the second coupling plate CP2.

The body part BM has a second thickness th2 equal to a sum of thethickness of the first coupling plate CP1 and the thickness of thesecond coupling plate CP2. In an exemplary embodiment, the thickness ofeach of the first and second coupling plates CP1 and CP2 is equal to ahalf of the thickness th2 of the body part BM, for example.

As shown in FIG. 4, the second coupling plate CP2 disposed at the otherend of the first chassis bar CB1 is disposed to overlap with the firstcoupling plate CP1 disposed at the one end of the second chassis bar CB2when viewed in a plan view. In this case, the lower surface of the firstcoupling plate CP1 of the second chassis bar CB2 makes contact with theupper surface of the second coupling plate CP2 of the first chassis barCB1, the third surface A3 of the first coupling plate CP1 of the secondchassis bar CB2 makes contact with the second surface A2 of the secondchassis bar CB1, and the fourth surface A4 of the second coupling plateCP2 of the second chassis bar CB1 makes contact with the first surfaceA1 of the first chassis bar CB2.

The first and second chassis bars CB1 and CB2 are fixed to the baseplate 110 using a fixing member. In an exemplary embodiment, the firstand second chassis bars CB1 and CB2 are fixed to the base plate 110 by afirst coupling screw SC1. In more detail, first and second holes H1 andH2 are defined in the first and second coupling plates CP1 and CP2include, respectively, and a third hole H3 is defined in the bottomportion 111 to correspond to the first and second holes H1 and H2. Thefirst coupling screw SC1 is engaged into the first to third holes H1 toH3. Accordingly, the first and second chassis bars CB1 and CB2 arecoupled to each other by the first coupling screw SC1, and the first andsecond chassis bars CB1 and CB2 are fixed to the base plate 110 by thefirst coupling screw SC1.

As described above, since the first and second coupling plates CP1 andCP2 are partially overlapped with each other while being coupled to eachother, the first and second chassis bars CB1 and CB2 are coupled to eachother by the first and second coupling plates CP1 and CP2, and thus thefirst and second chassis bars CB1 and CB2 are prevented from beingseparated from each other in a direction substantially vertical to alongitudinal direction of the first and second chassis bars CB1 and CB2.

FIG. 5 is a cross-sectional view showing a portion in which the secondside chassis bar is coupled to the second sidewall, and FIG. 6 is across-sectional view showing a portion in which the first side chassisbar is coupled to the first sidewall.

Referring to FIG. 5, the second side chassis bar SB2 has the samestructure and function as those of the first chassis bar CB1 except thatthe second side chassis bar SB2 does not include the first couplingplate CP1 (refer to FIG. 3). That is, the second side chassis bar SB2 isconfigured to include the body part BM and the second coupling plateCP2.

The second coupling plate CP2 of the second side chassis bar SB2 iscoupled to the first coupling plate CP1 of the first chassis bar CB1.The first surface A1 of the second side chassis bar SB2 makes contactwith a surface of the second sidewall SW2, which faces the first surfaceA1. The second side chassis bar SB2 is coupled to the second sidewallSW2 by a fixing member. The fixing member may be a second coupling screwSC2 engaged with the second sidewall SW2 and the second side chassis barSB2.

Referring to FIG. 6, the first side chassis bar SB1 has the samestructure and function as those of the second chassis bar CB2 exceptthat the first side chassis bar SB1 does not include the second couplingplate CP2 (refer to FIG. 3). That is, the first side chassis bar SB1 isconfigured to include the body part BM and the first coupling plate CP1.

The first coupling plate CP1 of the first side chassis bar SB1 iscoupled to the second coupling plate CP2 of the second chassis bar CB2.The second surface A2 of the first side chassis bar SB1 makes contactwith a surface of the first sidewall SW1, which faces the second surfaceA2. The first side chassis bar SB1 is coupled to the first sidewall SW1by a fixing member. In an exemplary embodiment, the fixing member may bea third coupling screw SC3 engaged with the first sidewall SW1 and thefirst side chassis bar SB1.

As described above, the first and second bent-maintaining members 120 aand 120 b include the first and second chassis bars CB1 and CB2.Accordingly, although a size of the base plate 110 (refer to FIGS. 1 and2) varies, the first and second bent-maintaining members 120 a and 120 b(refer to FIGS. 1 and 2) may be easily applied to the base plate 110 byadjusting the number of the first and second chassis bars CB1 and CB2 inaccordance with the size of the base plate 110.

In particular, the first and second chassis bars CB1 and CB2 may nothave a length longer than a specific length due to a limitation ofequipment used to manufacture the first and second chassis bar CB1 andCB2 and the first and second side chassis bars SB1 and SB2. When thelength of the base plate 110 is longer than the specific length, thefirst and second bent-maintaining members 120 a and 120 b may bemanufactured to have the length corresponding to the length of the baseplate 110 by using plural first chassis bars CB1 and plural secondchassis bars CB2, and thus the first and second bent-maintaining members120 a and 120 b may be coupled to the base plate 110.

FIG. 7 is a perspective view showing a chassis bar according to anotherexemplary embodiment of the present disclosure and FIG. 8 is an enlargedperspective view showing a portion in which the chassis bar shown inFIG. 7 is coupled to the bottom chassis.

Referring to FIGS. 7 and 8, a first chassis bar CB1′ includes a bodypart BM curved along the first direction D1, a coupling block CKdisposed at one end of the body part BM, and a coupling groove CGdefined in the other end of the body part BM.

The body part BM includes a first surface A1 disposed at the one endthereof to connect an upper surface of the body part BM and a lowersurface of the body part BM, and a second surface A2 disposed at theother end thereof to connect the upper surface of the body part BM andthe lower surface of the body part BM.

The coupling block CK includes a horizontal coupling protruding part HCKextending in a longitudinal direction of the body part BM from the firstsurface A1 and a vertical coupling protruding part VCK extending in adirection different from the longitudinal direction from an end of thehorizontal coupling protruding part HCK. In the illustrated exemplaryembodiment, the horizontal coupling protruding part HCK extendssubstantially in parallel to the first direction D1 and the verticalcoupling protruding part VCK extends substantially in parallel to thesecond direction D2 vertical to the first direction D1.

The horizontal coupling protruding part HCK has a plate-like shape in aplan view with the same width as that of the body part BM. In theillustrated exemplary embodiment, a side surface of the horizontalcoupling protruding part HCK extends from the side surface of the bodypart BM and is substantially in parallel to the side surface of the bodypart BM. The horizontal coupling protruding part HCK has a thirdthickness th3 smaller than the second thickness th2 of the body part BM.

The vertical coupling protruding part VCK has a plate-like shape in aside view with the same width as that of the body part BM and thehorizontal coupling protruding part HCK. In the illustrated exemplaryembodiment, a side surface of the vertical coupling protruding part VCKextends from the side surface of the horizontal coupling protruding partHCK and is substantially in parallel to the side surface of thehorizontal coupling protruding part HCK. The vertical couplingprotruding part VCK has a fourth thickness th4 smaller than the secondthickness th2 of the body part BM.

The side surface A2 of the other end of the body part BM is opened bythe coupling groove CG along the second direction D2. The couplinggroove CG includes a horizontal coupling groove portion HCG having ashape corresponding to the shape of the horizontal coupling protrudingpart HCK and a vertical coupling groove portion VCG having a shapecorresponding to the vertical coupling protruding part VCK.

In more detail, the horizontal coupling groove portion HCG is recessedfrom the second surface A2 to the longitudinal direction of the bodypart BM. The horizontal coupling groove portion HCG has a first width W1substantially the same as the third thickness th3 of the horizontalcoupling protruding part HCK.

The vertical coupling groove portion VCG has substantially the sameshape as that of the vertical coupling protruding part VCK. The verticalcoupling groove portion VCG is connected to the end of the horizontalcoupling groove portion HCG and extends in the second direction D2. Thevertical coupling groove portion VCG has a second width W2 substantiallythe same as the fourth thickness th4 of the vertical coupling protrudingpart VCK.

Referring to FIG. 8, the second bent-maintaining member 120 b includesfirst and second chassis bars CB1′ and CB2′ coupled to each other. Thesecond chassis bar CB2′ has the same structure and function as those ofthe first chassis bar CB1′, and thus detailed description of the secondchassis bar CB2′ will be omitted. The coupling groove CG defined at theother end of the first chassis bar CB1′ is overlapped with the couplingblock CK disposed at one end of the second chassis bar CB2′ when viewedin a plan view.

As described above, since the horizontal coupling groove portion HCG hasthe shape corresponding to that of the horizontal coupling protrudingpart HCK and the vertical coupling groove portion VCG has the shapecorresponding to that of the vertical coupling protruding part VCK, thehorizontal coupling protruding part HCK and the vertical couplingprotruding part VCK may be coupled to the horizontal coupling grooveportion HCG and the vertical coupling groove portion VCG, respectively.Therefore, the first and second chassis bars CB1′ and CB2′ are coupledto each other by the vertical coupling groove portion VCG and thevertical coupling protruding part VCK, and thus the first and secondchassis bars CB1′ and CB2′ are prevented from being separated from eachother in the first direction D1. In addition, the first and secondchassis bars CB1′ and CB2′ are coupled to each other by the horizontalcoupling groove portion HCG and the horizontal coupling protruding partHCK, so that the first and second chassis bars CB1′ and CB2′ areprevented from being separated from each other in the second directionD2.

The first and second chassis bars CB1′ and CB2′ are fixed to the baseplate 110 by a fixing member. In an exemplary embodiment, the first andsecond chassis bars CB1′ and CB2′ are fixed to the base plate 110 by afirst coupling screw SC1. In more detail, a fourth hole H4 is defined inthe horizontal coupling protruding part HCK, a fifth hole H5 is definedthrough the other end of the second chassis bar CB2′, the third hole H3is defined in the base plate 110.

The first coupling screw SC1 is engaged with the third, fourth, andfifth holes H3, H4, and H5. Thus, the first and second chassis bars CB1′and CB2′ are coupled to each other by the first coupling screw SC1 andfixed to the base plate 110 by the first coupling screw SC1.

FIGS. 9A to 9D are perspective views showing a method of manufacturingthe bottom chassis according to an exemplary embodiment of the presentdisclosure.

Referring to FIG. 9A, in an exemplary embodiment, the base plate 110including the bottom portion 111 and the first and second sidewalls SW1and SW2 is provided by the press molding process, for example. Thebottom portion 111 has the flat shape without being curved. In general,when an object is provided by the press molding process to be curved,the molding cost of the press molding process performed on the objectincreases and reliability on the press molding process is hardlyguaranteed. However, according to the exemplary embodiment, since thebottom portion 111 is provided to have the flat shape when initiallyprovided, the molding cost of the press molding process may be reducedand the reliability of the press molding process may be improved. In anexemplary embodiment, the base plate 110 may be provided bypress-molding a metal material, e.g., aluminum.

Referring to FIG. 9B, an extrusion plate EP is provided by the extrusionmolding process. The extrusion plate EP is provided by continuouslyextruding a material along the second direction D2. The extrusion plateEP has the shape curved along the first direction D1 substantiallyperpendicular to the second direction D2. The extrusion plate EPincludes a first coupling pattern PT1 provided at a first plate sideextending substantially in parallel to the second direction D2 and asecond coupling pattern PT2 provided at a second plate side extendingsubstantially in parallel to the second direction D2 and facing thefirst plate side.

Referring to FIG. 9C, the extrusion plate EP is cut along the firstdirection D1 into plural chassis bars CB each having a constant width inthe second direction D2. The chassis bars CB may be configured toinclude the first and second chassis bars CB1 and CB2. When theextrusion plate EP is cut as described above, the first and secondcoupling plates PT1 and PT2 may respectively serve as the first andsecond coupling plates CP1 and CP2 of the chassis bars CB.

Although not shown in figures, after the chassis bars CB are provided,the first and second side chassis bars SB1 and SB2 may be provided byremoving the first and second coupling plates CP1 and CP2.

Then, as shown in FIG. 9D, the second side chassis bar SB2, the firstchassis bar CB1, the second chassis bar CB2, and the first side chassisbar SB1 are connected to each other one after another, thus the firstand second bent-maintaining members 120 a and 120 b are provided.

The first and second chassis bars CB1 and CB2 are aligned such that thefirst and second holes H1 and H2 (refer to FIG. 4) are overlapped witheach other, and the first and second chassis bars CB1 and CB2 aredisposed on the bottom portion 111 to allow the first and second holesH1 and H2 to overlap with the third hole H3 (refer to FIG. 4) of thebottom portion 111.

When the first coupling screw SC1 is coupled to the first to third holesH1 to H3, the chassis bars CB adjacent to each other are coupled to eachother by the first coupling screw SC1 and the chassis bars CB are fixedto the bottom portion 111. The first sidewall SW1 is coupled to thefirst side chassis bar SB1 by the third coupling screw SC3 and thesecond sidewall SW2 is coupled to the second side chassis bar SB2 by thesecond coupling screw SC2.

The bottom portion 111 is curved along the first direction D1 tocorrespond to the shape of the chassis bars CB since the bottom portion111 has the flexibility.

Although the exemplary embodiments of the invention have been described,it is understood that the invention should not be limited to theseexemplary embodiments but various changes and modifications can be madeby one ordinary skilled in the art within the spirit and scope of theinvention as hereinafter claimed.

What is claimed is:
 1. A bottom chassis comprising: a base plate whichhas a flexibility and a first rigidity, includes a sidewall unitarytherewith and extending substantially perpendicular thereto, and iscurved along a first direction; and a bent-maintaining member whichcomprises a plurality of chassis bars which has a second rigiditygreater than the first rigidity, is curved along the first direction andcoupled to the base plate, and maintains a curved shape of the baseplate, wherein each of the plurality of chassis bars is coupled to anadjacent chassis bar thereto, and wherein at least one of the pluralityof chassis bars is directly coupled to the sidewall of the base plate bya fixing member disposed in holes defined in the at least one of theplurality of chassis bars and the sidewall of the base plate.